Apparatus for producing heat induced effects on flexible substrates

ABSTRACT

An apparatus for producing a chemical reaction or physical change on a flexible substrate, e.g., textile fabric, which comprises: means to impregnate the flexible substrate with a liquid substance capable of migrating through the application of heat; a heated die or roller means having a predetermined pattern so as to locally apply heat to said flexible substrate; transport means so as to transport the flexible substrate over the heated die or roller and in circumferential contact therewith so as to migrate the liquid substance to the surface of the flexible substrate in accordance with the predetermined pattern of the die or roller; and vacuum means associated with said heated die or roller so as to pull the heat radiated from the die or roller through and around the flexible substrate. Such use of vacuum means in association with the heated die or roller having a predetermined pattern eliminates water spotting which could occur on the flexible substrate. Such an apparatus can be utilized in conjunction with a system which includes a multiplicity of heated dies and rollers so arranged that the flexible substrate is made to travel an undulating or sinusoidal path around the same whereby the heated dies or rollers apply heat to opposite faces of the flexible substrate either locally or overall.

Unite States atet illiams [54] APPARATUS FOR PRODUCING HEAT INDUCED EFFECTS ON FLEXIBLE SUBSTRATES Primary Examiner-William 1. Price Attorney--Walter C. Kehm, Samson B, Leavitt and Martin Smolowitz [5 7] ABSTRACT An apparatus for producing a chemical reaction or physical change on a flexible substrate, e.g., textile fabric, which comprises: means to impregnate the flexible substrate with a liquid substance capable of migrating through the application of heat; a heated die or roller means having a predetermined pat tern so as to locally apply heat to said flexible substrate; transport means so as to transport the flexible substrate over the heated die or roller and in circumferential contact therewith so as to migrate the liquid substance to the surface of the flexible substrate in accordance with the predetermined pattern of the die or roller; and vacuum means associated with said heated die or roller so as to pull the heat radiated from the die or roller through and around the flexible substrate. Such use of vacuum means in association with the heated die or roller having a predetermined pattern eliminates water spotting which could occur on the flexible substrate.

Such an apparatus can be utilized in conjunction with a system which includes a multiplicity of heated dies and rollers so arranged that the flexible substrate is made to travel an undulating or sinusoidal path around the same whereby the heated dies or rollers apply heat to opposite faces of the flexible substrate either locally or overall.

12 Claims, 9 Drawing Figures atented March 14,

5 Sheets-Sheet 1 FIG.|

INVENTOR SUMNER HLWILLJAMS ATTORNEYS Patented March 14, $311 5 snwtwsmm 5 INVENTOR SUMNER wgugms ATTORNEYS Patented March 14, 172 3,648,488

5 Sheets-Sheet 4 INVENTOR SUMNER H. wlLLfAmg ATTORNEYS Patented March 14, W2 3,648,488

IN BNT R SUMNER HLWILLIAMS ATTORNEY APPARATUS FOR PRODUCING HEAT INDUCED EFFECTS ON FLEXIBLE SUBSTRATES In copending application Ser. No. 614,520 filed Feb. 7, 1967 in the names of Sumner H. Williams and Joseph R. Ellis, now U.S. Pat. No. 3,555,856, a process and apparatus are disclosed for an improvement in the customary practice of dyeing fabrics. Thus, the invention which is disclosed in such copending application comprises an improvement over the conventional process and apparatus wherein a fabric to be dyed is passed through a trough containing a dye whereby the fabric is padded to a substantially uniform shade or intensity and subsequently treated with a second dye after drying to provide a multi-colored effect on the opposite side of the material. Thus, in accordance with the invention disclosed in such copending application, it was determined that by application of the principle of physical or chemical change causing migration, previously considered detrimental to a dyeing process, it could be possible to provide a patterned or multicolored effect, i.e., an effect involving the formation of contrasting colors by subjecting a fabric material containing a dye or chemicals capable of being migrated to the action of a heated die or roller maintained at an elevated temperature. Thus, the apparatus disclosed in such copending application included means to impregnate the textile fabric with a liquid substance having migrating properties; a heated roller or die having the desired pattern; and transport means for transporting the textile material over the die or roller and in contact therewith. By application of the principle of migration such apparatus as disclosed in the aforementioned copending application is capable of producing the desired patterned effect since the dye tends to migrate to those areas of the fabric in contact with the heated die or roller.

In addition to the aforementioned means associated with such apparatus for developing a pattern on the surface of a textile material, such apparatus includes guide rollers which guide the textile material around the patterned or plain roller which because of their adjustable nature, are capable of controlling the extent of circumferential contact of the textile fabric with the heated roller.

In accordance with such apparatus, the production of the patterned effect on the textile or other flexible material could be achieved through contact of the textile or other flexible fabric with the heated roller for a period of time of from onehalf to 5 seconds, a time period much shorter than that achieved through any conventional means used in the prior art.

An improvement over such process and apparatus for effecting the physical migration of dyes to produce a multicolored or patterned effect on a textile fabric is set forth in a further application Ser. No. 660,167 filed Aug. 3, 1967, also in the names of Sumner H. Williams and Joseph R. Ellis, now U.S. Pat. No. 3,498,086. Such application describes an improved process and apparatus whereby the desired pattern is obtained on a textile fabric by preferentially migrating one dye or colorant over another. This is achieved by employing a means to dye the textile fabric with a first material having a certain background color; means to dye such textile material with a second color; and means to migrate and fix only the second color, such means again being a heated die or roller. In an alternative method employing alternative apparatus, a means to migrate the first color is employed subsequent to the first means to dye the textile fabric, the fabric having the migrated color being then passed through a second means, i.e., second bath, containing a second coloring agent together with reagents to reduce the migrated and second background color in order to fix them to the textile material. In accordance with still a further embodiment of such copending application, a single color is migrated by means of a pattern-carrying roller applied to one surface, the material being then contacted at its other surface with a heated roller to migrate the remaining dye in the other direction with respect to the thickness of the material. In such manner, it is possible to provide a dyed textile fabric wherein the contrast of dye migrated in the first direction by the first roller is enhanced.

A still further improvement over each of the processes and apparatus as set forth in the above-discussed copending applications is found in copending application Ser. No. 810,323 filed Mar. 25, 1969, also in the names of Sumner H. Williams and Joseph R. Ellis. Such copending application is directed to a process and apparatus for producing heat induced effects on textile fibers and fabrics. Thus, in accordance with the process and apparatus disclosed in such copending application, it has been discovered that by locally contacting a textile fabric or fiber containing a liquid reagent, it is possible not only to produce a patterned effect through the physical migration of dyes, chemicals, or similar pigments, but many other chemical reactions and physical changes can be efiected. Thus, for example, such apparatus as disclosed in this copending application can be employed for the heat fixation of dyes, chemicals, or pigments; for the development of dyes, chemicals or pigments by the reaction of two or more components or by heat induced transformation of an intermediate; for the curing of crease-proofing agents, cross-linking; agents, synthetic resins, natural gums, etc.; for the discharging or destroying of dyes, pigments, etc.; or for the drying of the flexible substrate. Thus, any and all of such chemical reactions and physical changes can be achieved on the textile fabric by contact of the same with one or more heated dies or rollers maintained at a temperature of from about 500 F. to about l,500 F., the contact with the heated surface being within a very short period of time, i.e., a fraction of a minute or second. Thus, it has been found in accordance with the invention developed and disclosed in such copending application that any and all of such chemical reactions or physical changes on the textile fabric or similar flexible substrate can be improved with respect to reproducability and time by treating the textile fabric or similar substrate for a very short period of time by contact with the heated die or roller.

Here again, the apparatus disclosed in this last mentioned copending application Ser. No. 810,323 generally comprises means for applying the necessary reactants or reagents for the chemical reaction or physical change to the flexible substrate; means to effect the chemical reaction or physical change through the application of heat, such means comprising at least one roller heated to a temperature within the range of about 500 F. to about l,500 F.; and means to transport the flexible substrate through such aforementioned means. It is additionally specified in accordance with the apparatus disclosed and claimed in such copending application that it is preferable that at least one roller carries a three-dimensional pattern and such apparatus additionally contains means to remove moisture from the flexible substrate, i.e., textile fabric, as the same leaves the means for applying the necessary reactants or reagents.

A still further improved apparatus is illustrated in application Ser. No. 833,128, filed June 13, 1969 also in the names of Sumner H. Williams and Joseph R. Ellis, now U.S. Pat. No. 3,523,435. In accordance with such application, an improved apparatus is described and claimed for producing any and all of the aforedescribed heat induced effects by the provision of a multiplicity of series of rollers having the ability to sequentially treat opposite sides of a flexible substrate, thereby producing distinct colorings on each side of the material by the use of two pad applications each containing different for mulations.

Thus, such apparatus in accordance with such application generally comprises a first means to apply a suitable liquid reagent to a suitable flexible substrate, i.e., textile fabric; a first heating means subsequent thereto to apply heat to a first face of the flexible substrate; a second means to apply a second liquid reagent to the flexible substrate subsequent to passage of the same over the first heating means; and a second heating means subsequent to second means to apply a second liquid reagent, the second heating means being adapted to apply heat to the second face of the flexible substrate. Each of the first and second heating means comprises a series of rollers so aligned that the flexible substrate is forced to follow an undulatory or sinusoidal path over each of said first and second heating means, the heated rollers of said first and second series of rollers being maintained at a temperature of from about 500 F. to about l,500 F.

It should be recognized that each of the above apparatus set forth in such applications involves the phenomenon of migration, whereby taking advantage of the migration of dyes, pigments, etc., to localized heated areas, it is possible to produce a variety of effects upon a flexible substrate e.g., textile fiber or fabric. In this regard, by taking advantage of the phenomenon of migration, it is possible through the local application of heat by contact with a patterned heated die or roller to migrate the dyestuff or similar material to the surface of the flexible substrate, thereby producing a variety of effects, such as a tone-on-tone effect through the single application of a dye. It has now been discovered in accordance with the present invention, however, that each of the systems described in such applications can be improved by providing a vacuum system in association with the heated die or roller or series of rollers, one of which is heated, and preferably patterned. Thus, it has been discovered in accordance with the present invention that by having a vacuum system in association with such heated die or roller, it is possible to produce greater effects taking advantage of the phenomenon of migration, since the use of the vacuum or exhaust system tends to pull the heat radiated from the die or roller both through and around the flexible substrate so that any trapped water vapors are prevented from condensing back on the substrate material. Thus, by applying a vacuum or exhaustsystem in association with the heated die or roller or series of heated dies or rollers, it is possible to prevent water spotting which might otherwise occur, absent the use of such systems. In this regard, as indicated previously, such use of a vacuum or exhaust system in association with the heated die or roller or series of dies or rollers in accordance with the present invention can be utilized in conjunction with any of the systems set forth in the aforementioned applications. Accordingly, such apparatus in accordance with the present invention can be associated with a system utilizing only a single heated die or roller so as to contact one surface of the flexible substrate, or can be used in association with a system whereby opposite faces of the flexible substrate are contacted with a heated die or roller. Accordingly, the apparatus of the present invention comprises an improvement in any and all of the aforedescribed systems.

Accordingly, it is a principal object of the present invention to provide an improved apparatus for providing or producing heat induced effects on flexible substrates, e.g., textile fabrics, which apparatus improves that of the prior art by allowing for the production of greater effects in a manner not heretofore possible.

It is a further object of the present invention to provide a novel apparatus for the production of heat induced effects on flexible substrates, whereby through the phenomenon of migration, an effect is produced on the flexible substrate through localized contact of the same with a heated die or roller, such die or roller or series of dies or rollers having as- I sociated therewith a vacuum or exhaust system.

It is yet a further object of the novel apparatus of the present invention to provide a system wherein an exhaust or vacuum is associated with the heated die or roller or series of dies and rollers effective to produce a heat induced effect upon a flexible substrate, such use of the exhaust or vacuum system preventing the water vapors evolved from the contact with the heated roller from condensing back on the flexible substrate, thereby eliminating the problem of water spotting associated with previous apparatus.

Still further objects and advantages of the novel apparatus of the present invention will become more apparent from the following more detailed description thereof in association with the accompanying drawings wherein:

FIG. 1 is a schematic illustration of the apparatus of the present invention showing a side elevation view of one embodiment thereof;

FIG. 2 is an enlarged side elevation view of an embodiment of the present invention illustrating overhead removal of water vapor by vacuum;

FIG. 3 is a front elevation view of the apparatus illustrated in FIG. 2;

FIG. 4 is a partial front elevation view of a further embodiment in accordance with the present invention;

FIG. 5 is a further partial front elevation view illustrating a still further embodiment of the present invention;

FIG. 6 is a schematic view illustrating an overall system utilizing the improved apparatus of the present invention;

F IG. 7 is a schematic view illustrating a further embodiment of the present invention showing an optional cooling means;

FIG. 8 is a further schematic view illustrating another embodiment of the present invention showing an alternative cooling means; and

FIG. 9 is a perspective view of a suitable heated die or roller employed in accordance with any of the embodiments of the present invention.

Referring now to the drawings wherein like reference numerals designate like or corresponding parts'throughout'the various views, there is shown in FIG. I a continuous flexible substrate, such as a textile fabric 10 which may, for example, be a cotton twill or similar material. The flexible substrate 10 is passed over a guide roller 12, in the form of a suitable input roller, and subsequently into a suitable vessel 14, i.e., a pad box or dye vat or a similar means capable of applying a liquid reagent to the flexible substrate 10. The particular composition of the liquid reagent, i.e., dye, etc., will depend upon the chemical reaction or physical change that is desired through subsequent utilization of the apparatus of the present inventionQWith respect to the migration of dyes, the only important requirement for the liquid reagent or dye in the pad box or dye vat 14 is that such material have the ability to migrate in the flexible substrate under the influence of subsequently applied heat.

After the flexible substrate 10 has passed through vessel 14 and the liquid reagent impregnated thereon, the flexible substrate 10 is preferably passed through squeeze rollers 16 wherein a portion of the liquid reagent is removed so as to control the moisture content of the flexible substrate 10. Generally, by passing the flexible substrate 10 through squeeze rollers 16, the moisture content of the flexible substrate 10 is controlled so that the same is within the range of about 30 percent to about percent by weight based on the weight of the dry flexible substrate, the moisture content being preferably in the region of about 75 percent by weight. As shown in FIG. 1, the squeeze rollers 16 are preferably arranged in such a manner that any excess liquid reagent is returned automatically, by example, by gravity to vessel 14.

The flexible substrate 10, after leaving the squeeze rollers 16, passes over a number of guide rollers 12 and compensator rollers 24. The guide rollers 12 merely guide the flexible substrate 10 through the apparatus of the present invention while the compensator rollers 24 act to maintain the proper position and tension within the flexible substrate 10. Such compensator rollers 24 may be adjustable in position, weighted, spring loaded, or otherwise suitably arranged in a manner well known in the art.

The flexible substrate 10 containing the suitable chemical reagent from vessel 14 is then passed over a heating means which, in accordance with the present invention, comprises a series of rollers, preferably a series of heated and unheated rollers 18 and 20, respectively. By such an arrangement, it is possible to apply heat to one face of the textile substrate 10. Alternatively, however, it should be quite clear that each of the rollers which are shown in FIG. 1 as being three in number can be heated so as to provide heat to both faces of the flexible substrate 10 within this one heating means. As will'be illustrated hereinafter, in connection with FIG. 6, it is possible in accordance with the present invention to provide a first heating means to apply heat to one face of the flexible substrate 10, and thereafter a' second heating means to apply heat to the opposite face of the flexible substrate.

As shown in FIG. 1, such series ofrollers 18 and 20 are illustrated as being three in number, aithough it should be obvious that any number can be advantageously utilized. Again, it is pointed out that the series of rollers can comprise a series of heated and unheated rollers or, alternatively, a series of heated rollers. To take advantage of the migration phenomenon which occurs in accordance with the present invention, however, at least one of the rollers must be suitably heated.

As shown in FIG. 1, the series of rollers utilized in accordance with the present invention is so arranged that the flexible substrate is caused to take a sinusoidal or undulating path around the rollers whereby one or two faces of the flexible substrate 10 are brought into contact with the heated surfaces. Assuming that only rollers 18 are heated, in accordance with one embodiment of the present invention, only one face of the flexible substrate 10 will be brought into contact with the heated rollers in accordance with such an embodiment of the present invention. If each of rollers 18 and are heated, however, the two faces of the flexible substrate 10 would be alternatively contacted with the heated surfaces.

Preferably, but not necessarily, in accordance with the present invention, at least one of the heated rollers, i.e., rollers 18, carries a three-dimensional design or pattern. The use of a heated roller having a three-dimensional pattern or design is particularly advantageous wherein the apparatus of the present invention is utilized to achieve localized chemical reactions or physical effects upon the moving flexible substrate 10. Thus, by providing a raised pattern or design on the heated roller, only the raised portion is in contact with the moving flexible substrate 10 to the effect that the heat of the heated roller is localized at such points of contact. Accordingly, utilizing the physical migration of dyes as an example, by employing the heated roller having a three-dimensional pattern or design, it is possible to produce a multi-tone effect since the dye is preferentially migrated to those areas only which are contacted by the heated member. This, therefore, can produce any type of desired design based solely upon the design or pattern ofa heated roller. Such use ofa heated die or roller having a three-dimensional pattern or design so as to effect a multi-tone product through the migration of dyes, pigments, and similar materials is more fully discussed in copending application Ser. No. 810,323, filed Mar. 25, 1969, the disclosure ofwhich is herein incorporated by reference.

Additionally, while not being shown in FIG. 1, it is preferable in accordance with the present invention that each of the heated rollers, i.e., rollers 18, have associated therewith a heat shield located partially or substantially around the heated roller 18 but allowing sufficient space so that the flexible substrate can pass in contact with the heated roller without contacting the heat shield. Such heat shield, of course, has the obvious function of reflecting the heat back to the area of the heated roller so that excessive heat does not escape to the surrounding areas. Such heat shields are generally about one-half to 1 inch away from the roller and are produced from a conventional material, i.e., asbestos, calcilite, etc., capable of reflecting the heat back to the area of the heated rollers.

As indicated previously, the present invention has an advantage over those systems previously described in that recondensation of the evolved water vapor or water spotting offlexible substrate 11) is avoided by the provision of a vacuum system, which draws off the evolved water vapor. Such a system comprising one embodiment of the present invention is schematically illustrated in FIG. 1. Thus, a housing or conduit 26 surrounds the series of rollers 18 and 20 so that the heat of the rollers is not dissipated to the general atmosphere and so that the evolution of water vapor through the local application of heat can be controlled to avoid the aforementioned difficulties.

In order to prevent the water vapor which is evolved by the contact of the heated rollers with the flexible substrate 10, a vacuum system is provided, the same being diagrammatically illustrated by fan 28. As shown in FIG. 1, the use of such a vacuum or exhaust system pulls the heat radiated from the rollers both through and around the ends of the flexible substrate 10 so that trapped water vapors are prevented from condensing back on the flexible substrate. This use of the vacuum or exhaust system therefore eliminates water spotting on materials as occurs in the use of previously developed apparatus. Accordingly, the use of the vacuum or exhaust system in accordance with the novel apparatus of the present invention increases the drying efficiency of materials by making use of the hot air that is nonnally lost to the atmosphere. Such exhaust or vacuum system will be further described by reference to FIGS. 2-5.

After the flexible substrate 10 leaves the heating means comprising the series of heated and unheated rollers 18 and 20, the same travels around a series of guide rollers 12 to transport the flexible substrate 10 from the heating means to the eventual takeup rolls. Thus, in accordance with the apparatus shown in FIG. 1, the flexible substrate 110, which has been heated in accordance with the present invention, is passed over and around guide rollers 12 and through feed rolls 30 prior to be taken up on a takeup roll, not shown. Accordingly, such guide rollers 12 and feed rolls 30 comprise suitable means for transporting the flexible substrate 10 through the apparatus of the present invention.

FIGS. 2 and 3 more clearly illustrate the aforedescribed heating means in accordance with one embodiment of the present invention. It can be seen by reference to the rollers illustrated that, in accordance with the heating means shown, the flexible substrate 10 is caused to follow a sinusoidal or undulating path around rollers 18 and 20, such rollers constituting a series of rollers in accordance with the present invention.

As seen in FIGS. 2 and 3, in accordance with this embodiment, the first and third rollers 18 are heated and attached to a frame 68 by which such rollers 18 can be lifted transversely to the direction of the movement of the fllexible substrate so as to move the same out of alignment with the remaining roller 20 not so attached to frame 68. Such lifting of the frame 68 and attached rollers 18 is achieved through the provision of a hydraulic lift schematically illustrated by reference to hydraulic cylinder 70. The features of such a hydraulic system capable of lifting frame 68 and associated rollers 18 are, of course, well known and well adaptable to the apparatus of the present invention.

Frame 68 also has attached to the same a motor 62, the motor 62 being capable of driving the rollers 18 and 20 through a drive chain 64 and sprockets 66 associated with each ofthe rollers 18 and 20.

As can be seen from FIGS. 2 and 3, the motor 62 attached to the frame 68, being of any conventional type electric or similar motor, permits the constant movement of the three rolls illustrated through the provision of a single chain drive mechanism. Thus, as represented in FIGS. 2 and 3, the motor 62 through chain 64 and sprocket 66 will drive the first or entry roller 18 in a clockwise direction, the second or middle roller 20 in a counterclockwise direction and the third or exit roller 18 in a clockwise direction. This, of course, allows for the contact of the flexible substrate 10 on its upper top surface only with the heated rollers 18.

As indicated above, however, if roller 20 is also heated, the undulatory path traveled by the flexible substrate 10 in accordance with the present invention will allow for the heating of the textile material on both faces at the same time. However, it is preferred in accordance with the present invention that the rollers be arranged such as in FIGS. 2 and 3 so as to provide a heating of the flexible substrate 10 only on one face. In this regard, as will be described hereinafter with respect to FIG. 6, a still further system utilizing the novel apparatus of the present invention can contain a further or second heating means wherein the undulatory path traveled by the flexible substrate will allow the same to be heated on the face opposite that heated in the first heating means such as illustrated in FIGS. 2 and 3.

As can be seen from the schematic representation in FIGS. 2 and 3, when frame 68 is lifted through the hydraulic lift and associated hydraulic cylinder 7 sprocket 66 of roller 20 will become disengaged from chain 64 to the effect that the rotation of roller 20 will stop. When in operational position, however, chain 64 becomes engaged with sprocket 66 so that the in concert movement or rotation of the rollers as aforementioned takes place. It will also be observed from FIGS. 2 and 3 that the arrangement illustrated is such that, due to the fact that the rollers 18 and motor 62 are attached to frame 68 capable of being lifted through the hydraulic cylinder 70, the entire chain drive mechanism is lifted out of operational align- Y ment upon the upward movement offrame 68.

Additionally, while not illustrated in FIG. 2, the apparatus of the present invention, specifically the first and second heating means, can additionally have an overriding clutch associated with the motor and chain drive mechanism so as to permit faster speeds when the rollers are in alignment or to permit the disengagement of the heated rollers 18 when raised.

As indicated previously with respect to FIG. 1, each of the heated rollers 18 preferably has a heat shield 30 associated therewith. As shown in FIGS. 2 and 3, such heat shield 30 associated with each of the heated rollers 18 is composed of one or more upper and lower sections surrounding the heated roller yet allowing sufficient space for passage of the flexible substrate in contact with the heated rollers 18. Such heat shields 30 are preferably spaced about one-half to 1 inch away from the roller so as to allow the contact of the flexible substrate 10 with the heated roller 18 yet retain the substantial portion of the heat in the areas of the roller. As shown in FIGS. 2 and 3, the upper sections of the heat shield 30 are preferably attached to movable frame 68 so as to move therewith while the lower sections of the heat shield 30 are permanently affixed to the support 32 of the apparatus.

FIG. 3 additionally illustrates the provision of guide rails 72 attached to the hydraulic system and employed to maintain the guide rollers in the proper position and alignment when raised in accordance with the procedure described above.

As seen in FIGS. 2 and 3, the heating means comprising the series of rollers I8 and 20 is within a housing or conduit 26, the upper portion of which is connected to a vacuum or exhaust system schematically illustrated by fan 28. The embodiment illustrated in FIGS. 2 and 3 is such that the exit for evolved water vapor is directly overhead of the series of rollers 18 and 20, such that the water vapor evolved and the heat given off from the heated roller 20 is not dissipated to the atmosphere, but is drawn out through the top of enclosure 26. By using such exhaust or vacuum system to pull the heat radiated from the rollers both through and around the ends of the flexible substrate 10, the trapped water vapors are prevented from condensing back on such flexible substrate. Accordingly, the use of such a vacuum or exhaust system in accordance with the present invention eliminates water spotting on the materials when utilizing the apparatus of the present invention. In addition, the use of such system increases the drying efficiency of materials by making use of the hot air that is normally lost to the atmosphere.

In accordance with the present invention, the exhaust or vacuum system that is utilized can comprise any conventional system capable of drawing a vacuum within enclosure 26. As indicated previously, such a system has been schematically and diagrammatically illustrated by fan 28. It should be recognized, however, that any conventional type of exhaust or vacuum system capable or reducing the pressure and withdrawing the heat and water vapor can be advantageously utilized in accordance with the novel apparatus of the present invention. In this regard, such an exhaust or vacuum system should be such that the pressure within enclosure 26 is reduced to about 1 mm. to about 16 mm. Hg so that the evolved water vapor and heat radiated from the rollers is pulled through and around the flexible substrate. Accordingly, the use of such a vacuum or exhaust system in accordance with the novel apparatus of the present invention eliminates water spotting on the flexible substrate which would occur absent the use of such exhaust or vacuum. In addition, the use of the exhaust or vacuum system in accordance with the present invention increases the drying efficiency of the apparatus by making use of the hot air that is normally lost to the atmosphere.

Further embodiments and modifications of the apparatus shown in FIGS. 2 and 3 are shown in FIGS. 4 and 5. Thus, such figures show in partial schematic view various modifications of the exhaust system in accordance with the present invention. As seen in FIG. 4, the water vapor and housing evolved from roller 18 are drawn through husing or conduit 26 by means of a vacuum or exhaust system designed by fan 28. In the embodiment shown in FIG. 4, the housing or conduit 26 is illustrated only on one side of the rollers 18 and 20. Such an embodiment differs from that illustrated in FIG. 5 wherein the housing or conduit 26 is on both sides of the rollers so as to draw the heat evolved and the water vapor evolved through such housing or conduit by means of a vacuum or exhaust system illustrated by fan 28. Both embodiments illustrated in FIGS. 4 and 5 are effective in accordance with the present invention to pull the heat radiated from the rollers both through and around the ends of the flexible substrate material. In this way, the problem of water spotting on such flexible substrate is eliminated in that the evolved water vapor does not tend to condense back on the flexible substrate material. In addition, drying efficiency is improved in that the hot air normally exhausted to the atmosphere is utilized.

It should be noted that while FIGS. 2-5 show various embodiments of the present invention through various arrangements of the housing or conduit 26 and exhaust or vacuum system designated by fan 28, any such system can be advantageously utilized in accordance with the apparatus of the present invention. In this regard, it should be quite obvious that other equivalent systems can be utilized as long as they allow for the withdrawal of the heat and water vapors evolved so as to prevent the problem of water spotting associated with recondensation of the water vapor upon the flexible substrate from which the same is withdrawn. Accordingly, the use of the vacuum or exhaust system of the present invention allows for an improvement in the conventional apparatus wherein, for example, a multitone effect is produced on a flexible substrate by taking advantage of the phenomenon of migration.

As indicated previously, the novel apparatus of the present invention can be utilized in a system wherein a multiplicity of heating means are provided whereby such multiplicity of heating means are employed to alternatively heat opposite faces of the flexible substrate. Such a system is shown, for example, in FIG. 6. As seen in FIG. 6, a continuous flexible substrate, such as textile fabric 10, is passed over a guide roller 12 in the form of a suitable input roller, and subsequently into a suitable vessel l4, i.e., a pad box or dye vat or a similar means capable of applying a liquid reagent to the flexible substrate 10. It is, of course, obvious that the particular composition within the vessel 14 will depend upon the chemical reaction or physical change that is desired in accordance with the use of the novel apparatus of this invention. With respect to the migration of dyes, however, it is only essential that the liquid reagent or dye in the vessel 14 be such a material that the same has the ability to migrate in the flexible substrate under the influence of subsequently applied heat.

After the flexible substrate 10 is passed through vessel 14 and the liquid reagent impregnated thereon, the flexible substrate 10 is preferably passed through squeeze rollers 16 wherein a portion of the liquid reagent is removed so as to control the moisture content of the flexible 10. Generally, by passing the flexible substrate 10 through squeeze rollers 16, the moisture content of the flexible substrate 10 is controlled so that the same is within the range of about 30 percent to about percent by weight based on the weight of the dry flexible substrate, the moisture content being preferably in the region of about 75 percent by weight. As shown in FIG. 6, squeeze rollers 16 are preferably arranged in such a manner that any excess liquid reagent is returned automatically, for example, by gravity to vessel 14.

The flexible substrate 10, after leaving the squeeze rollers 16, passes over a number of guide rollers 12 and compensator rollers 24. The guide rollers 12 merely guide the flexible substrate through the apparatus of the present invention while the compensator rollers 24 act to maintain the proper position and tension within the flexible substrate 10. Such compensator rollers 241 may be adjustable in position, weighted, spring loaded, or otherwise suitably arranged in a manner well known in the art.

The flexible substrate 10 containing the suitable chemical reagent from the vessel 14 is then passed over a heating means comprising a series of heated and unheated rollers 18 and 20, respectively. As shown in FIG. 6, such series or rollers 18 and are shown to be three in number, although it should be obvious that any number can be advantageously utilized. In accordance with the present invention, the series or rollers is so arranged that the flexible substrate 10 is caused to take a sinusoidal or undulating path around the rollers whereby one face only of the flexible substrate 111 is brought into contact with the heated surfaces. In accordance with the embodiment of the present invention illustrated in FIG. 6, the first and third rollers 18 are heated, such rollers being in contact with the upper or top face of the flexible substrate 10. The rotation of the rollers 18 and 20 of the first series of rollers comprising the first heating means is preferably accomplished through a motor, chain drive, and sprocket arrangement (shown in FIGS. 2 and 3) whereby the rotation and speed of rollers can be accurately regulated.

Preferably, but not necessarily, in accordance with the present invention, at least one of the heated rollers 18 carries a three-dimensional design or pattern. The use of a heated roller 18 having a three-dimensional pattern or design is particularly advantageous wherein the apparatus of the present invention is utilized to achieve localized chemical reactions or physical effects upon the moving flexible substrate 10. Thus, by providing a raised pattern or design on the heated roller 18, only the raised portion is in contact with the moving flexible substrate 10 to the effect that the heat of the heated roller 18 is localized at such points of contact. Accordingly, using the physical migration of dyes as an example, by employing the heated roller having a three-dimensional pattern or design, it is possible to produce a multi-tone effect since the dye would be preferentially migrated to those areas only which are contacted by the heated member. This, therefore, can produce any type of desired design based solely upon the design or pattern of the roller. Such use of a heated die or roller having a three-dimensional pattern or design so as to effect a multitone product through the migration of dyes, pigments, and similar materials is more fully discussed in copending application Ser, No. 810,323 filed Mar. 25, 1969, disclosure ofwhich is herein incorporated by reference.

As indicated previously, the second or middle roller 20 is preferably a roller which is not heated and which need not be capable of being raised out of alignment with the other rollers of the series of rollers of the first heating means. Accordingly, by providing the middle or second roller 20 as one which is unheated, the flexible substrate 10 when traveling the undulating path around the rollers 18 and 20 will be contacted on only on face, i.e., the upper face, with the heated rollers 18. This, therefore, allows a preferential chemical reaction or physical change to take place at this point in the apparatus only on the upper face of the flexible substrate 10.

As can be seen from FIG. 6, when heated rollers 18 are raised in position 18 through means as illustrated in connection with FIGS. 2 and 3, the flexible substrate 10 does not travel the undulatory or sinusoidal path around the rollers 18 and 20, but merely travels in a straight path between guide rollers 12. When the heated rollers 18 are in operative position, that is, form a series of heated and unheated rollers, the flexible substrate is caused to travel such undulatory or sinusoidal path such that one face of the flexible substrate 10 is brought into contact with the heated rollers 18.

After leaving the last heated roller 18, the flexible substrate 10 then passes over a number of guide rollers and compensating or tension rollers again employed to maintain the tension of the system at its proper level. Thus, the compensator or tension rollers 24 are employed as takeup devices with the proper tension to make certain that enough cloth is available to engage the rollers when the heated rollers in series are in operative position. When the heated rollers are retracted, the compensating or tension rollers take up slack in cloth to their normally idle position.

After passing over a series of guide rollers 12 and tension rollers 24, the flexible substrate 11) .is caused to pass into a second vessel 21 capable of applying a second liquid reagent to the flexible substrate 10. Such second vessel 21 preferably comprises a dye or chemical pad or vat. When employing the apparatus of the present invention to produce a multicolor effect through the migration of dyes, this second vessel 21 would contain a suitable dye which when padded onto the flexible substrate 10 and subsequently contacted with heated rollers would be capable of being migrated.

After passing through the suitable vessel for applying the second liquid reagent 21, the flexible substrate 11 would again preferably pass through squeeze rollers 22 which again control the moisture content of the flexible substrate 10. Here again, squeeze rollers 22 are arranged so that: the moisture content of the flexible substrate 10 leaving squeeze rollers 22 is within the range of 30 to percent by weight based upon the weight of the dry flexible substrate 10. Again, such squeeze rollers 22 are arranged so that the excess moisture removed from the flexible substrate 10 flows back through gravity into vessel 21.

After passing over the last of guide rollers 12, as shown in FIG. 6, the flexible support 10 is passed into contact with a second heating means comprising a plurality of rollers, again shown as three. Thus, in accordance with the embodiment shown in FIG. 6, the flexible support 10 first contacts a heated roller 34, then an unheated roller 36, and last a second heated roller 34. As seen in FIG. 6, the relationship of the rollers constituting this second heating means is such that the flexible substrate 10 is caused to contact the heated rollers 34 only on that surface not contacted by the heated rollers when the flexible substrate 10 passes through the first heating means. Accordingly, such an arrangement allows for the sequential heat treatment of opposite faces of the flexible substrate 10 so as to allow for the sequential effecting of chemical reactions or physical changes on opposite faces of the suitable flexible material.

As shown in FIG. 6, both the guide rollers immediately prior to and preceding the series of rollers and the middle unheated roller 36 are adjustable in position to positions 12 and 36. Here again, this is done so as to provide for a means by which the sinusoidal or undulatory travel of the flexible substrate 10 can be omitted when operation of the heating means is not desired or where prolonged contact of the flexible substrate 10 with the heated rollers 34 must be avoided so as to eliminate any deleterious effects. This may occur, for example, wherein the apparatus malfunctions for some reason and prolonged contact of the flexible substrate 10 with the heated rollers 34 may cause damage to the flexible material.

After leaving the second heating means comprising the second series of heated and unheated rollers 34 and 36, the flexible substrate 10 is then passed over a number of guide rollers and compensating rollers and subsequently to a suitable takeup device, not illustrated.

Further embodiments illustrating optional features in accordance with the present invention are shown in FIG. 7 and 8. In this regard, it has been discovered in accordance with the present invention that when a cold or wet flexible textile material is passed over the heated rolls as in accordance with the present invention, there is somewhat of a tendency that the edges of the textile material become over-heated or scorched due to the excessively high temperature of the roll in those areas past the contact between the textile material and heated roll surface. Accordingly, if such radiated heat is not controlled or dissipated there is a tendency that the textile material at the edges may be scorched or otherwise damaged due to the excessive heat.

Alternate means to control this phenomenon are shown in the embodiments illustrated in FIGS. 7 and 8. Reference to FIG. 7 reveals that the same illustrates a three-roll system such as shown, for example, in the latter half of FIG. 6, such system comprising heated rolls 34 and an unheated roll 36. The

system is arranged as in accordance with FIG. 6 so that guide rolls l2 and unheated rolls 36 can be moved out of engagement with the flexible textile into positions 12 and 36' so that upon stoppage of the apparatus for any reason, excess heating of the textile material will not occur.

Additionally, however, FIG. 7 shows an additional means which can be utilized in accordance with the present invention to reduce any tendency that might be present for the textile material to be scorched or otherwise damaged at its edges from the excessive heat radiated from the heated rollers 34. Such an additional means as shown in FIG. 7 comprises a conduit 40 which allows the flow of air through air jets 42, the air impinging upon the surface of the heated roll not in contact with the textile material 10. The flow of air through conduit 40 and jets 42 is controllable by means of a suitable valve means 44. By allowing the air to impinge upon the surface of the heated roll 34 it has been found that the excess heat is dissipated so that any tendency for scorching or otherwise damaging the flexible textile 10 is eliminated.

It is, of course, obvious that the air velocity, air temperature, volume of air and the number of jets utilized are controllable so as to provide any degree of cooling found necessary. Accordingly, while FIG. 7 illustrates the use of three jets it is, of course, obvious that any suitable number can be utilized in order to effect the necessary cooling of the heated roller 34 so as to prevent damage to the flexible textile 10. Additionally, while FIG. 7 illustrates the use of the cooling means only in conjunction with one of the heated rollers 34, it should be obvious that such means can be employed in conjunction with both or all of the heated rollers so as to eliminate any problem associated with overheating.

FIG. 8 shows a further means for eliminating the problem of scorching which again might occur if, for example, the width of the textile material 10 varies as the textile is being processed in accordance with the apparatus of the present invention. Again, it is pointed out that the embodiment shown in FIG. 8 prevents any scorching or other damage to the flexible textile material 10 which might occur at the edges thereof due to excess heat radiated from the heated roller. The embodiment shown in FIG. 8 allows dissipation of the heat by having surface openings 50 located on the heated roller 34 beyond the point where the roller is contacted with the flexible textile 10. In this regard, by having such surface openings the excessive heat built up within the heated roller is dissipated so that the same does not adversely effect the characteristics of the flexible textile 10. Here again, it should be quite obvious that the number of such surface openings 50 as well as well as the diameter thereof can be varied in accordance with the present invention to obtain any desired degree of cooling necessary to eliminate the scorching problem. Additionally, it should be quite obvious that where still further control of the temperature of the heated roller 34 is necessary to prevent damage to the flexible textile 10, the embodiments shown in FIGS. 7 and 8 can be conjointly utilized.

As indicated previously, it is preferred in accordance with the present invention that the heated rollers utilized have a three-dimensional or raised pattern. In this regard, FIG. 9 illustrates a variety of patterns which could be utilized in connection with a heated roller in accordance with the present invention. Thus, for example, such a pattern-carrying roller, as shown in FIG. 4, may consist of a cylindrical element 80 supplied with means to heat the element, shown, for example, as internal electrical heating unit 81 and 82 suitable connected internally and brought out into electrical contact by, for example, slip rings well known in the art (and only schematically illustrated in FIG. 9) for further connection to a supply of electrical power. Thus, for example, the heating element 81 and 82 within the hollow shell of the pattern-carrying roller can comprise conventional quartz elements capable of producing the necessary heat at the surface of the roller.

While the embodiment shown in FIG. 9 illustrates the use of electrical elements to heat the roller in accordance with the present invention, it should be, of course, obvious that other conventional and equivalent heating means such as heated gases can be utilized to provide the heated surface on the roller so as to achieve the effects associated with the apparatus of the present invention. Accordingly, any and all such means effective to produce the necessary heated surface are well within the scope of the present invention.

In order to produce a longitudinal stripe pattern, for example, through the migration of a dye using such a pattern-carrying roller, cylindrical body 80 is supplied with a circumferential ridge 85. Thus, using'the above-described apparatus of the present invention, if theheated rollers of the heating means contain only such circumferential ridges, the migration would produce a fabric having a surface which contained rather well-defined ridges of coloration upon a lighter background.

The remaining types of three-dimensional designs shown in connection with FIG. 9 are representative of those which can be employed in accordance with the utilization of a patterncarrying in accordance with the apparatus of the present invention. Thus, for example, the employment of a roller carrying a ridge 86 with holes 87 would produce a fabric after migration which would have dark stripes including spots of color substantially the same as the background. Similarly, employing a pattern-carrying roller including projections 88 would provide a fabric after migration which would have series of dark spots upon a lighter background, since the color or dye would tend to be migrated to the raised areas contacted by the heated roller.

Lastly, for example, a mottled effect could be produced by employing a heated roller having a ridge or series of ridges 89 having a knurled or serrated appearance. In this connection, a closely knurled roller will produce substantially an overall effect, i.e., an overall migration of the dye to the surface in contact with the heated roller, which overall effect is well defined, thereby providing a preference for such a knurled roller over a smooth roller, as described previously.

It should be clear from a review of FIG. 9 that any combination or variation of such three-dimensional design can be utilized to the effect that through the utilization of the present invention, any possible contrasting effect through the migration of dyes can be achieved.

It is additionally pointed out that the use of the apparatus of the present invention, including the vacuum or exhaust system described, provides for a greater effect than heretofore possible with conventional apparatus since the disadvantages of water spotting, etc., are eliminated. This, therefore, constitutes an advantage of the novel apparatus of the present invention over any and all previously developed systems.

While the above-described apparatus of the present invention has been presented primarily with respect to the use of such apparatus for the migration of dyes, it is, of course, obvious that the apparatus disclosed and illustrated above can be employed to provide any and all types of heat induced effects on the flexible substrate, i.e., textile fabric. Here again, reference is made to copending application Ser. No. 810,323 which indicates that a similar system can be suitably employed to produce a physical migration of dyes, chemicals, or pigments; heat fixation of dyes, chemicals or pigments; development of dyes, chemicals, or pigments by the reaction of two or more components or by heat induced transformation of an intermediate; curing of crease-proofing agents, cross-linking agents, synthetic resins, natural gums, etc.; discharging or destroying of dyes, pigments, etc.; or drying of a flexible substrate.

What is claimed is:

1. Apparatus for producing a chemical reaction or physical change on a flexible substrate through the application of heat, said apparatus comprising in combination:

means for applying a liquid reagent to said flexible substrate, said chemical reagent being capable of migration in said flexible substrate by the application of heat;

heating means to apply heat to said flexible substrate by physical contact therewith, said heating means including at least one heated roller, heated to a temperature of 500-l ,500 F.;

transport means adapted to transport said flexible substrate from said means for applying a liquid reagent through said heating means and in physical contact with said heated roller thereof;

a conduit so located with respect to said heated roller of said heating means as to allow the water vapor evolved and heat radiated from said heated roller to pass through said conduit;

and vacuum means associated with said conduit as to draw said evolved water vapor and radiated heat therethrough.

2. The apparatus of claim 1 further including means to remove moisture from said flexible substrate located between said means to apply said liquid material and said heating means.

3. The apparatus of claim 1 wherein said heating means includes a series of heated and unheated rollers around which said flexible substrate travels an undulatory path.

4. The apparatus of claim 3 wherein at least one of said heated rollers carries a three-dimensional pattern.

5. The apparatus of claim 1 wherein said heated roller carries a three-dimensional pattern.

6. The apparatus of claim 1 further including subsequent to said heating means a second heating means including at least one roller heated to a temperature of 500-1,500 F.; a conduit so situated with respect to said heated roller as to allow the water vapor evolved and heat radiated from said heated roller to pass through said conduit; and a vacuum means associated with said conduit to draw said water vapor and heat therethrough.

7. The apparatus of claim 6 further including a second means for applying liquid reagent capable of being migrated by the application of heat located prior to said second heating means.

8. The apparatus of claim 7 further including subsequent to said second means for applying said liquid reagent and prior to said second heating means, a second means to remove moisture from said flexible substrate.

9. The apparatus of claim 6 wherein each of said heating means includes a series of heated and unheated rollers around which said flexible substrate travels an undulatory path.

10. The apparatus of claim 9 wherein each of said heating means includes a heated roller carrying a three-dimensional pattern.

11. The apparatus of claim 9 wherein the series of heated and unheated rollers of said first and second heating means are so arranged that said flexible substrate when traveling an undulatory path around the rollers of said second heating means is contacted with the heated rollers of said second heating means on the face opposite that contacted by the heated rollers of said first heating means when said flexible substrate travels an undulatory path therearound.

12. The apparatus of claim 1 further including means associated with the heated rollers so as to cool the surface thereof not in contact with the flexible substrate. 

1. Apparatus for producing a chemical reaction or physical change on a flexible substrate through the application of heat, said apparatus comprising in combination: means for applying a liquid reagent to said flexible substrate, said chemical reagent being capable of migration in said flexible substrate by the application of heat; heating means to apply heat to said flexible substrate by physical contact therewith, said heating means including at least one heated roller, heated to a temperature of 500* 1,500* F.; transport means adapted to transport said flexible substrate from said means for applying a liquid reagent through said heating means and in physical contact with said heated roller thereof; a conduit so located with respect to said heated roller of said heating means as to allow the water vapor evolved and heat radiated from said heated roller to pass through said conduit; and vacuum means associated with said conduit as to draw said evolved water vapor and radiated heat therethrough.
 2. The apparatus of claim 1 further including means to remove moisture from said flexible substrate located between said means to apply said liquid material and said heating means.
 3. The apparatus of claim 1 wherein said heating means includes a series of heated and unheated rollers around which said flexible substrate travels an undulatory path.
 4. The apparatus of claim 3 wherein at least one of said heated rollers carries a three-dimensional pattern.
 5. The apparatus of claim 1 wherein said heated roller carries a three-dimensional pattern.
 6. The apparatus of claim 1 further including subsequent to said heating means a second heating means including at least one roller heated to a temperature of 500* - 1,500* F.; a conduit so situated with respect to said heated roller as to allow the water vapor evolved and heat radiated from said heated roller to pass through said conduit; and a vacuum means associated with said conduit to draw said water vapor and heat therethrough.
 7. The apparatus of claim 6 further including a second means for applying liquid reagent capable of being migrated by the application of heat located prior to said second heating means.
 8. The apparatus of claim 7 further including subsequent to said second means for applying said liquid reagent and prior to said second heating means, a second means to remove moisture from said flexible substrate.
 9. The apparatus of claim 6 wherein each of said heating means includes a series of heated and unheated rollers around which said flexible substrate travels an undulatory path.
 10. The apparatus of claim 9 wherein each of said heating means includes a heated roller carrying a three-dimensional pattern.
 11. The apparatus of claim 9 wherein the series of heated and unheated rollers of said first and second heating means are so arranged that said flexible substrate when traveling an undulatory path around the rollers of said second heating means is contacted with the heated rollers of said second heating means on the face opposite that contacted by the heated rollers of said first heating means when said flexible substrate travels an undulatory path therearound.
 12. The apparatus of claim 1 further including means associated with the heated rollers so as to cool the surface thereof not in contact with the flexible substrate. 